BondPilot has received an Innobooster grant from the Innovation Fund Denmark to develop the world’s first technology for precise application, monitoring, and dosing of hot-melt adhesive in the production of wind turbine blades.

Modern wind turbine blades are made from fiberglass and PU foam, which are temporarily bonded with epoxy prior to vacuum infusion. However, data from European offshore wind farms show that errors in the bonding process account for 17% of all operational shutdowns, making them both costly and resource-intensive. At the same time, existing bonding methods are often based on solvent-containing aerosols, leading to excessive adhesive use, increased environmental impact, and health risks for operators.

With the grant from Innovation Fund Denmark, BondPilot can complete the development of its fully automated hot-melt adhesive spray gun and integrate the company’s patented Coat Weight Control (CWC) technology, which uses AI-based image analysis to monitor and control adhesive dosing in real time.

The BondPilot solution:

• Ensures uniform and correct adhesive application
• Operates independently of operator experience
• Reduces material consumption, production defects, and physical strain in manufacturing

The technology is aimed at the global wind turbine industry and has further significant scaling potential within the marine and construction industries. The project helps strengthen Denmark’s position in sustainable manufacturing technology and renewable energy.